installation instructions

installation instructions

INSTALLATION INSTRUCTIONS

1984 ‒ 2001 Jeep Cherokee XJ

For Rancho Suspension Systems:

RS66002 — fits Chrysler 8.25” Rear Axle

RS66003 — fits Dana Rear Axle

- INSTALLATION OF A SLIP YOKE ELIMINATOR AND REPLACEMENT DRIVESHAFT ON THE STOCK TRANSFER CASE IS RECOMMENDED -

WARNING

Carefully read, understand and follow the instructions provided in this manual, and keep it in a safe place for future reference. If you have any doubt whatsoever regarding the installation or maintenance of your Rancho suspension system, please see your retailer for assistance or advice. Failure to follow the warnings and instructions provided herein can result in the failure of the suspension system, or can cause you to lose control of your vehicle, resulting in an accident, severe personal injury or death.

These instructions should remain in the vehicle glove box for future reference.

Rancho Suspension 89002 Rev B

WARNING: READ ALL INSTRUCTIONS

THOROUGHLY FROM START TO FINISH BEFORE

BEGINNING INSTALLATION. Failure to follow the warnings and instructions provided herein can result in an accident, severe personal injury or death.

PRELIMINARY

This manual presumes that all persons installing this suspension system have a high level of mechanical training and experience, and have available to them all necessary tools and safety equipment. This manual is not and should not be construed as an exhaustive list of all required safety measures. Personnel should rely primarily on their training and experience, as well as on their own common sense.

This Manual is to be read as a supplement to, and must not be construed as a substitute for, the owner’s manual and/or shop manual that originally accompanied the vehicle. Refer to such use, operation, maintenance and safety manuals as necessary, and especially after installation is complete, to insure proper vehicle operation.

The following terminology has been used in this Manual:

I.

ACCIDENT:

Any event which could cause personal injury or death to anyone installing or using the suspension system, as well as to passengers and bystanders, or otherwise may result in property damage.

PRE-INSTALLATION WARNINGS and INSTRUCTIONS

WARNING: Only the following rim/tire sizes may be used with this suspension system:

31 x 10.50 x 15 tire on a 15” x 8” wheel with 3.75”

Backspacing. See important Note M

Use of any other rim/tire combination increases the risk of a roll-over and/or accident, resulting in severe personal injury or death.

WARNING: This suspension system will enhance the off-road performance of your vehicle. It will handle differently; both on and off-road, from a factory equipped passenger car or truck. Failure to drive this vehicle safely may result in serious injury or death to the driver and passengers. ALWAYS

WEAR your seat belts, REDUCE your speed, and

AVOID sharp turns and other abrupt maneuvers.

1) Service and repair tasks require specialized knowledge, training, tools, and experience. General mechanical aptitude may not be sufficient to properly install this suspension system. If you have any doubt whatsoever regarding your ability to properly install the suspension system, please consult a qualified mechanic.

2) Your brake lines and fuel lines should remain undisturbed during and after installation. If you think you need to modify these components in any way, you are mistaken. You are installing the lift improperly and will be creating a significant risk of an accident. In case of any doubt, consult a qualified mechanic.

3) If any component does not fit properly, something is wrong.

You are installing the lift kit improperly and will be creating a significant risk of an accident. Never modify any component of the vehicle or suspension system, except as instructed herein. Do not continue with installation until you have identified the problem.

4) Several of the procedures described herein require at least two

(2) persons to safely complete the task. If you have any doubt about your ability to complete any operation by yourself, always ask for help from a qualified assistant.

5) Before starting any operation, confirm that all personal safety devices and safety equipment are in proper condition and position.

6) Give your work undivided attention. Looking around, carrying on a conversation and "horse-play" are careless acts that can result in an error in installation and/or serious injury.

7) Install only tires approved by the United States Department of

Transportation (“DOT approved”). Make sure the rim and tire size are properly matched.

8) If any components of the vehicle or suspension system are damaged in any way during installation, immediately replace the component.

9) During installation, carefully inspect all parts of the vehicle and replace anything that is worn or damaged.

10) Nip points present the risk of the catching, lacerating, crushing and/or amputating fingers, hands, limbs and other body parts during operations. Always keep clear. Wear protective gloves.

11) Oil and hydraulic fluids are poisonous, dangerous to health and are known to the State of California to cause cancer, birth defects or other reproductive harm. Do not inhale vapors or swallow. Do not allow contact with the eyes or skin. Should any oil or fluids be swallowed or inhaled or come into contact with the eyes, immediately follow the safety precautions on the label or call a poison control center immediately. Should any of the oil or fluids contact your skin, immediately wash thoroughly.

12) Never install the suspension system if you are under the effects of alcohol, medications and/or drugs. If you are taking prescription or over the counter medication, you must consult a medical professional regarding any side effects of the medication that could hinder your ability to work safely.

WARNINGS and INSTRUCTIONS

AFTER INSTALLATION

13) After installation is complete, drive the vehicle slowly in an area free from heavy traffic for at least three (3) miles. Likewise, before traveling on any highways or at a high rate of speed, drive the vehicle for ten (10) miles on side roads at moderate speed. If you hear any strange noise or feel unusual vibration, if a component of the suspension system is not operating properly, or if any warning lights illuminate or buzzers sound, stop the vehicle immediately. Identify the cause and take any necessary remedial action.

2

15) Confirm that all components of the vehicle, including all lights

(headlights, turn signals, brake lights, etc.), linkages (accelerator, etc.), electrical switches and controls (windshield wipers and defoggers, etc.), and other warning devices (low tire pressure monitoring systems) are fully operational.

16) Your headlights will need to be readjusted before the vehicle is used on the roads. Consult the vehicle owners’ manual.

17) The speedometer and odometer will need to be recalibrated after installation. See your dealer.

18) Confirm proper rear view and side view while seated in the driver seat. Install supplemental mirrors as necessary.

19) Your original low tire pressure monitoring system may be reinstalled in your new wheels. However, if you choose to purchase a new system, see your dealer to have them properly calibrated.

Proper tire pressure is critical to safe operation of the vehicle.

OPERATION

20) Because it has been modified, the vehicle will not handle, turn, accelerate or stop in the same manner as an unmodified vehicle. In addition, the crash protection systems designed in the vehicle may operate differently from an unmodified vehicle. For example, turning and evasive maneuvers must be executed at a slower rate of speed.

Further, there is a greater risk that the vehicle could roll over. These differences could result in an increased possibility of an accident, personal injury or death. Learn the vehicle’s operations and handling characterizes and drive accordantly.

IMPORTANT NOTES

A. Before installing this system, have the vehicle’s alignment and frame checked by a certified technician. The alignment must be within factory specifications and the frame of the vehicle must be sound (no cracks, damage or corrosion).

B. The components of Rancho’s suspension system are designed as a single integrated system. To avoid compromises in terms of safety, performance, durability or function, do not substitute Rancho components with components manufactured by other companies.

Use of other components will result in the forfeiture of any type of warranty on the vehicle/suspension system.

New Rancho shock absorbers are required and must be purchased separately.

Front

RS7239

RS999239

Rear

RS7256*

RS999256*

RS55239

RS5239

RS55245

RS5256*

*

Lower mounting bushing replacement required.

C. Do not powder-coat or plate any of the components in this system. To change the appearance of components, automotive paint can be applied over the original coating.

D. Each hardware kit in this system contains fasteners of high strength and specific size. Do not mix hardware kits or substitute a fastener of lesser strength. See bolt identification table on page 4.

E. Compare the contents of this system with the parts list in these instructions. If any parts are missing, contact the Rancho Technical

Department at 1-734-384-7804.

3

F. Install all nuts and bolts with a flat washer. When both SAE

(small OD) and USS (large OD) washers are used in a fastener assembly, place the USS washer against the slotted hole and the

SAE washer against the round hole.

G. Apply a drop of thread locking compound to all bolts during installation. CAUTION: Thread locking compound may irritate sensitive skin. Read warning label on container before use.

H. Unless otherwise specified, tighten all nuts and bolts to the standard torque specifications shown in the table on page 2. USE A

TORQUE WRENCH for accurate measurements.

I. Some of the service procedures require the use of special tools designed for specific procedures. The following tools and supplies are recommended for proper installation of this system: If you do not know how to safely use any of these tools, stop the project and consult a qualified mechanic.

Jeep Service Manual

Spring Compressor

Drill Motor

Drill assortment (1/8” to 1/2”)

Torque Wrench (250 FT-LB capacity)

Hammer

1/2” Drive Ratchet and Sockets

Combination Wrenches

Flair Nut Wrenches

Allen Wrenches

Torx Key Sockets

Hacksaw

File

Large "C" Clamps and/or Bench Vise

Hydraulic Floor Jack

Heavy Duty Jack stands

Wheel Chocks (Wooden Blocks)

Anti-Seize Compound

Synthetic Grease

Silicone Spray

Safety Glasses--Wear safety glasses at all times

J. It is extremely important to replace coil springs, CV flanges, and front drive shaft/pinion relationships as original. Be sure to mark left/right, front/rear, and indexing of mating parts before disassembly.

A paint marker or light colored nail polish is handy for this.

K. Suspension components that use rubber or urethane bushings should be tightened with the vehicle at normal ride height. This will prevent premature failure of the bushing and maintain ride comfort.

L. The required installation time for this system is approximately 5 to 6 hours. Check off the box ( ) at the beginning of each step when you finish it. Then when you stop during the installation, it will be easier to find where you need to continue from.

M. This suspension system was developed using a 31 x 10.50 x 15 tire on a 15” x 8” wheel with 3.75” of backspacing. Before installing any other combination, consult your local tire and wheel specialist.

Actual tire size varies by manufacturer.

O. The lifespan of Rancho products depends on many factors.

Improper use, abuse or harsh use in general may compromise the integrity of the suspension system and significantly reduce its lifespan. The suspension system is also subject to wear over time.

Have the suspension system regularly inspected and maintained by qualified mechanics. If the inspection reveals any damage or excessive wear, no matter how slight, immediately replace or repair the component. The suspension system must be regularly maintained in order to optimize its safe and efficient use. The more severe the conditions under which the suspension system is operated, the more often it must be inspected and maintained.

Inspect components for wear, damage and proper fastener torque each time vehicle is driven off-road.

N. Important information for the end user is contained in the consumer/installer information pack. If you are installing this system for someone else, place the information pack on the driver’s seat.

Please include the installation instructions when you finish.

Compatible With OE

Wheels

Yes

1

Development Tire Size (actual)

31x10.5xR15

Bolt Size

5/16

3/8

7/16

1/2

9/16

5/8

3/4

INCH SYSTEM

Grade 5

15 FT-LB

30 FT-LB

45 FT-LB

65 FT-LB

95 FT-LB

135 FT-LB

185 FT-LB

Optional Tire Size

1

(actual)

33x12.5xR15

Wheel Size (backspacing)

STANDARD BOLT TORQUE & IDENTIFICATION

METRIC SYSTEM

Grade 8

20 FT-LB

35 FT-LB

60 FT-LB

90 FT-LB

130 FT-LB

175 FT-LB

280 FT-LB

Bolt Size

M6

M8

M10

M12

M14

M16

M18

Class 9.8

5 FT-LB

18 FT-LB

32 FT-LB

55 FT-LB

85 FT-LB

130 FT-LB

170 FT-LB

Class 10.9

9 FT-LB

23 FT-LB

45 FT-LB

75 FT-LB

120 FT-LB

165 FT-LB

240 FT-LB

15x8 (3.75”)

Class 12.9

12 FT-LB

27 FT-LB

50 FT-LB

90 FT-LB

145 FT-LB

210 FT-LB

290 FT-LB

The driver of this suspension system recognizes and agrees that there are risks inherent in driving a vehicle with a lifted suspension system, including but not limited to the risk that you could be involved in an accident that would not occur in an unmodified vehicle. By his/her purchase and use of this suspension system, the user expressly, voluntarily and knowingly accepts and assumes these risks, and agrees to hold Tenneco, Inc. and its related companies harmless to the fullest extent permitted by law against any resulting damages.

4

10

9

Box 1 of 4

4

9

11

13

15

Box 2 of 4

16

13

14 14

8

8

2

2

7

5

3

7

1

9

7

8

11

10

5

6

4

3

2

ITEM PART #

RS66002-1

1

RS66003-1

RS822

RS176080

RS860793

RS520080

RS420080

RS7852

RS7853

RS176695

RS176647

RS860726

RS770173

RS860794

RS520094

DESCRIPTION

BOX 1

Jeep Front Coil 4"

Lower Control Arm

Sub Assy, Lower Bushing

Articulation Bushing

Sleeve 2.5" Long

Shim - .04"

Shim - .120 "

Upper Control Arm

Rod End

Sub Assy - Jam Nut

Jam Nut, 7/8-14

Sub Assy,Upper Bushing

Articulation Bushing

RS420103

RS176086

RS602612

Sleeve - 2.0" Long

Track Bar

T-Bar Rod End

RS860157 Sub Assy, Track Bar

RS520086-10 Track Bar Bushing,

RS420086

RS770070

RS770114

RS7713

RS860795

RS770271

RS176443

RS176339

RS176300

RS860797

RS545

RS420084

RS78341

RS78371

RS7726

RS7914

RS7911

RS7915

RS7719

RS170081

Sleeve 1.60" Long

Jam Nut, 3/4-16

Cotter Pin

HHTS, 3/8-16 X 1.5

Sub Assy - Lock Nut

Nut 1/2-20 Lock Nut

Front Bumpstop Spacer

Sway Bar End Link

Clevis, Sway Bar

Sub Assy, Sway Bar End Link

Bushing, EB1 Hour Glass

Sleeve .688 X .522 X 1.40

HHCS 7/16-14 X 1.25

NUT 7/16-14 Top Lock

Washer 7/16 SAE

HHCS, M12-1.75X65MM

Nut, M12-1.75 Top Lock

Washer, M12

Washer, 1/2 USS

Brake Line w/ Copper Washers, R

RS170082

RS980

Brake Line w/ Copper Washers, L

Rear Lower Shock Bushing Kit

1036000032 Bushing, Straight

RS94180

RS89002

Information Pack

Instruction

6

1

QTY

4

2

2

4

2

1

4

2

1

1

1

1

1

2

1

1

1

2

1

1

2

2

4

2

1

2

1

1

1

2

2

1

2

1

4

1

2

2

1

8

4

8

4

2

12

15

16

14

13

12

12

ITEM PART #

RS66002-2

1

RS66003-2

2

RS746

1

RS741

2

RS420072

RS454

DESCRIPTION

Box 2

Kit, U-Bolt – Chrysler 8.25” Rear Axle

Kit, U-Bolt, Dana Rear Axle

Sleeve, 2.74” Spring / Shackle

Sleeve, 3.20” Forward Leaf Pivot

RS575

RS626

RS7455

1

RS74051

2

RS8011

RS7722

Bushing, Forward Leaf Pivot

Bushing; Spring / Shackle

QTY

1

1

4

2

4

8

U-Bolt 1/2-20 X 3.125 X 6.55 (Chrysler) 4

U-Bolt 1/2-20 X 2.75 X 7.50 (Dana) 4

RS7723

RS8882

RS176767

RS860791

RS626

Sub Assy, 1/2" Nut

Nut, 1/2-20 Nylock

Washer, 1/2 SAE

Instruction

XJ Rear Shackle

Sub Assy, XJ Rear Shackle

Bushing; Spring / Shackle

1

8

8

1

2

1

4

RS420111 Xj Rear Shackle Sleeve

RS176409

RS860796

RS7733

RS770241

RS170119

RS7500

Rear Bumpstop Bracket

Sub Assy, Rear Bumpstop

Washer, 5/16 USS

HHCS,M8-1.25X25MM

RS770128 Washer, M8

RS603112 Nut, M8-1.25 Nylock

Rear Brakeline XJ

Leaf Shim 2.5 Deg

4

4

1

2

2

2

1

8

4

1

Box RS66002-2 includes U-bolt kit RS746 with U-bolts RS7455 to fit Chrysler 8.25” Rear Axle.

2

Box RS66003-2 includes U-bolt kit RS741 with U-bolts RS74051 to fit Dana Rear Axle.

Box 3 of 4

17

ITEM PART #

RS66002-3

17

RS66003-3

RS44148

17

DESCRIPTION

Box 3

Rear XJ Leaf Spring

Box 4 of 4

5

ITEM PART #

RS66002-4

17

RS66003-4

RS44148

DESCRIPTION

Box 4

Rear XJ Leaf Spring

1

1

QTY

1

1

QTY

6

Pitman Arm

Sway Bar End Link

Sway Bar End Link

T

RACK

B

AR

& C

FRONT SUSPENSION

OIL

S

PRING

R

EMOVAL

1)

Park the vehicle on a level surface. Set the parking brake and chock rear wheels. Measure and record the distance from the center of each wheel to the top of the fender opening.

See Illustration 2. Record these measurements in the space provided below.

Illustration 1

3)

Remove the cotter pin and nut from the ball stud end of the track bar at the frame rail bracket. Separate the ball stud from the bracket using a puller or “pickle fork” separator.

Alternatively reinstall retaining nut a few threads, and use a tie strap to pull down on the track bar, then turn steering wheel side to side. See Illustration 1.

4)

Raise the front of the vehicle and support the frame with jack stands. Remove the front wheels and set them aside.

5)

Position a floor jack under the front axle for support.

6)

Remove both front sway bar end links.

7)

Remove bolts and separate the brake hoses from the frame rails. See Illustration 3. If necessary, disconnect any vent hoses and electrical wiring from the axle.

8)

Remove the bolt and flag nut from the track bar axle bracket. Remove the track bar.

Illustration 2

2)

Utilizing a straight edge, measure the horizontal distance between the outer edge of each front tire and the vehicle body (at top edge of fender well).

Left Side:_________ Right Side:_________

9)

Disconnect the drag link at the pitman arm by removing the cotter pin and retaining nut and separating with a puller.

Alternatively, reinstall retaining nut a few threads, and use a tie strap to pull down on the drag link while hitting the end of the pitman arm with a hammer. Take care not to damage ball joint, pitman arm or steering box.

10)

Remove the shock absorber lower nuts and bolts.

Remove the upper stud nut, retainer and grommet from both front shock absorbers. Remove the front shock.

DO NOT REUSE ORIGINAL SHOCK ABSORBERS

7

Shock Absorber

Upper Control Arm

Bump Stop Mount

Bump Stop

Brake Hose

Lower Control Arm

Brake Caliper

Illustration 3

11)

Remove the rubber bump stop. Remove bump stop mount if it is bolted on behind the rubber bump stop.

C

ONTROL

A

RM

R

EPLACEMENT

1)

Lubricate the outside diameter of two urethane bushings

RS520080 from bag RS860793 with a silicone spray or a thin coat of synthetic grease.

2)

Press the lubricated bushings into one end of a new

Rancho control arm RS176080 as shown in Illustration 4.

3)

Lubricate the outside diameter of sleeve 420080 and the inside diameter of the installed urethane bushings with synthetic grease. Press the sleeve into the bushings.

5)

Repeat steps 1 through 4 for the remaining lower arm ends, bushings, and sleeves.

6)

Repeat steps 1 through 4 with rod end RS176647 using bushings RS520094 and sleeves RS420103 from bag

RS860794.

7)

Install jam nut from bag RS860794 on rod end

RS176647 until 5-6 threads are left. Apply anti-seize compound or grease and thread rod end into upper control arm RS176695.

Adjust length to 15.2”

CAUTION: Keep control arms attached on one side at all times to prevent axle from rotating.

8)

Remove the passenger side lower control arm from the axle and frame bracket. Retain bolts and nuts as they will be used later for installing the new lower control arms. See

Illustration 3.

9)

Carefully lower the axle assembly using the jack.

Loosen the spring retainer and remove the coil spring.

CAUTION: Do not allow the front axle to hang by any hoses or cables.

10)

Remove the passenger side upper control arm from the axle and frame bracket. Retain bolts and nuts as they will be used later for installing the new lower control arms.

RS822

RS170082

RS176695

RS176443

Illustration 4

NOTE: It may be necessary to use a rubber mallet, bench vise or C-clamp to press the bushings and sleeves into the arms. Do not use a metal hammer.

4)

Slowly apply grease to each end of the arms (through the grease fitting) with a grease gun. Stop when the grease begins to appear around the edges of the bushings. Do not force the bushings out of the arm.

8

RS176080

Shims (at Axle and Frame Mount)

Illustration 5

11)

Loosely attach rod end of Rancho upper control arm to frame bracket with the original hardware. Loosely attach bracket end of upper control arm to the axle bracket with the original hardware. See Illustration 5.

12)

Determine the shims required for the frame and axle end of the lower control arm. See Illustration 4 and Illustration 5.

Usually these are:

Early model XJ = 2 Thin Shims ‒ .040”, RS7852

Later model XJ= 2 Thick Shims ‒ .120”, RS7853

Verify the shim selection by placing the selected washers onto the sleeve on the assembled Rancho lower control arm and inserting into frame and axle mount.. Adjust the number of washers, if required. You should not need to force the combination into the pocket.

13)

Once shim selection is determined lightly grease the shims.

14)

Loosely attach the rear of the Rancho lower arm

RS176080 to the frame with the selected shims and OE hardware. Position the arm with the shorter bent side forward.,

The straight-out grease fitting is located under the axle, and the upper fitting points down and to the rear.

15)

Loosely attach the front of the Rancho arm, using OE hardware and selected shims between the bushing and the axle bracket. Be sure to lightly grease the shims before installation.

16)

Repeat steps 8-15 for driver side.

17)

Tighten lower control arms to 135 Ft-Lbs. Tighten upper control arm at the frame to 35 Ft-Lbs. DO NOT TIGHTEN

UPPER CONTROL ARMS AT AXLE until vehicle is on the ground at ride height.

B

UMP

S

TOP

S

PACER

, C

OIL

S

PRING

& S

HOCK

A

BSORBER

I

NSTALLATION

Sway Bar

RS176300 OE Bump Stop

RS602612

RS822

RS176086

1)

Drill a 5/16" hole through the center of the coil spring axle pad. For ease of installation, tap the hole (3/8-16).

2)

Install original insulator on top of coil spring RS822.

Place bump stop spacer RS176443, OE bump stop and bump stop mount inside the coil spring.

NOTE: If you have a winch mounted to the front bumper, optional spring spacer RS70082 (purchased separately) may be added to compensate for the additional weight.

3)

Insert the spring assembly into the upper mount and onto the axle pad. Align pig tail with groove in axle pad. Install coil retainer and torque to 16 Ft-Lbs.

4)

Re-install OE bump stop mount and rubber bump stop.

5)

Attach the Rancho bump stop spacer to the axle pad with the self-tapping screw from RS860157.

6)

Repeat steps 1 through 4 for the other side.

7)

Install retaining washer and bushing on NEW Rancho shock absorber. Insert shock into upper mounting hole. Install bushing, washer and nut. Tighten nut until bushings compress.

Repeat for other side.

8)

Raise front axle and attach shock lower mounts to axle brackets with the original hardware. Tighten nuts and bolts to 14

Ft-Lbs.

B

RAKE

H

OSE

R

EPLACEMENT

NOTE: To keep the brake bleeding process to just the front calipers, do not allow the brake fluid to drain completely from the master cylinder reservoir.

Use flare nut wrench on tube fittings to prevent stripping nuts.

1)

Before removing OE brake hose, loosen and re-snug connections at metal brake tube and caliper to ensure connections move freely. See Illustration 3.

2)

Separate the left front brake hose from the brake tube and the frame rail. Plug tube to prevent brake fluid leakage.

3)

Remove the brake hose from the caliper. Discard copper washers.

4)

Attach left brake hose RS170082 to the caliper with

NEW COPPER washers supplied with brake hose, and the original bolt. See Illustration 7. Tighten the bolt to 23 ft.-lbs.

RS176443

RS176339

1/2” USS Washer

Illustration 6

9

New Copper Washers

Illustration 7

5)

Attach the new brake hose to the frame and brake tube.

Tighten securely. See Illustration 5.

6)

Repeat steps 1 through 5 to install right front brake hose

RS170081.

7)

Refill the master cylinder reservoir with approved brake fluid and bleed the front brakes as follows:

A.

Attach a clear hose to the right front caliper bleeder screw and immerse the other end into a container of clean brake fluid.

B.

Loosen the bleeder valve on the caliper.

C.

Have an assistant push the brake pedal down and then hold.

D.

Tighten the bleeder valve and slowly release the pedal.

E.

Repeat the procedure until all air is purged from the caliper.

F.

Attach the hose and container to the left front caliper and repeat the bleeding process. Refill the brake master cylinder reservoir as necessary.

8)

Check lines for leaks. Tighten tube fitting 1/8” turn if leak occurs. Over tightening will damage flare fitting.

Do not exceed 23 ft.-lbs. on caliper bolt

S

WAY

B

AR

E

ND

L

INK

I

NSTALLATION

.

1) □

Using a silicone spray, press the supplied bushings

RS545 and sleeves RS420084 from bag RS860797 into new end links RS176339. Use a bench vise, C-clamp or arbor press.

See Illustration 6.

2)

Install sway bar clevis RS176300 to the end of the sway bar using 7/16” hardware from bag RS860797. Torque to 60 Ft-

Lbs.

3)

Attach end links to axle bracket with the original bolts and large 1/2” USS washers from hardware bag RS860797.

4)

Attach end links to sway bar clevis with the 12MM hardware from bag RS860797. Tighten upper and lower end link hardware to 60 Ft-Lbs.

T

RACK

B

AR

I

NSTALLATION

1)

Reconnect the drag link to the pitman using the retaining nut. Torque to 35 Ft-Lbs. Install new cotter pin.

2)

Install the jam nut from bag RS860157 on the new track bar end RS602612. Thread the end assembly into the new track bar RS176086 until only four threads are exposed. Do not tighten the jam nut. See Illustration 6.

3)

Apply silicone spray or synthetic grease and press the bushings and sleeve from bag RS860157 into the track bar assembly.

4)

Loosely attach the new track bar to the axle bracket with the original bolt and flag nut.

5)

Temporarily attach the track bar end to the frame rail bracket.

6)

Install front wheels and lower vehicle to the ground.

Tighten lug nuts to 80-110 FT-LBS.

7)

Repeat tire to fender well measurements (refer back to step 2 under Track Bar Removal). If necessary, adjust the track bar end to duplicate the previously measured difference.

Tighten the jam nut.

8)

Torque the track bar to axle bracket mounting bolt to 45 ft. lbs. and the ball stud nut to 35 ft. lbs. Slowly tighten castle nut up to 1/8 turn to line up cotter pin hole (See Note). Install a new cotter pin.

NOTE: After torqueing, if OE castle nut will not thread on track bar ball joint stud enough to insert cotter pin, replace castle nut with 1/2” center lock nut RS770271 from bag RS860795.

9)

Torque upper control arms at axle to 45 Ft-Lbs.

10

REAR SUSPENSION

1)

Park the vehicle on a level surface. Set parking brake and chock front wheels. Raise the rear of the vehicle and support the frame with jack stands.

2)

Remove the rear wheels.

B

RAKE

H

OSE

R

EPLACEMENT

NOTE: To keep the brake bleeding process to just the rear brakes, do not allow the brake fluid to drain completely from the master cylinder reservoir.

Use flare nut wrench on tube fittings to prevent stripping nuts.

1)

Before removing OE brake hose, loosen and re-snug brake hose to metal brake tube connections to ensure connections move freely. See Illustration 8.

Vent Hose Fitting

RS170119

8)

Refill the master cylinder reservoir with approved brake fluid and bleed the rear brakes as follows:

A.

Attach a clear hose to the right rear brake cylinder bleeder screw and immerse the other end into a container of clean brake fluid.

B.

Loosen the bleeder valve on the caliper.

C.

Have an assistant push the brake pedal down and then hold.

D.

Tighten the bleeder valve and slowly release the pedal.

E.

Repeat the procedure until all air is purged from the caliper.

F.

Attach the hose and container to the left rear brake cylinder and repeat the bleeding process. Refill the brake master cylinder reservoir as necessary.

9)

Check lines for leaks. Tighten tube fitting 1/8” if turn leak occurs. Over tightening will damage flare fitting.

10)

Remove axle vent fitting to detach hose from axle.

S

HOCK

B

USHING

R

EPLACEMENT

Replace lower shock bushings if using RS7256, RS999256 or,

RS5256.

Replacement bushing NOT REQUIRED for RS55245.

1)

Lube bushing and sleeve with spray lube.

2)

Using an arbor press, vise, or c-clamp, press out sleeve at least half way. Use a socket or pipe against the lower mounting loop and a socket or bolt against the sleeve. See

Illustration 9. Sleeve can then be removed with pliers.

Illustration 8

2)

Remove clip holding brake hose to frame bracket.

3)

Remove vent hose from axle vent fitting. Remove vent fitting to disconnect brake hose from axle.

4)

Disconnect brake hose from metal brake tubes at axle.

Plug brake hose to prevent exes fluid from leaking.

5)

Connect Rancho rear brake hose RS170119 to metal brake tubes at axle. Attach new hose to axle with vent hose fitting and snug brake tube connection nuts.

6)

Disconnect brake hose from metal brake tube at frame bracket.

7)

Connect Rancho rear brake hose to metal brake tube at frame bracket. Install clip to hold brake hoe to frame bracket.

Snug brake tube connection nut.

Socket

Mounting Loop

Socket

Illustration 9

3)

Use same large socket or pipe against mounting loop and another socket against bushing to remove bushing.

4)

Clean mounting loop and lube loop and new bushing

1036000032 from kit RS980 with soapy water or silicon spray lube.

11

5)

Press bushing into loop using 9/16 x 3” bolt, nut and washers. Press in by threading nut onto bolt. See

6)

Illustration 10 and Illustration 11.

New Bushing

L

EAF

S

PRING AND

S

HACKLE

R

EPLACEMENT

1)

Press larger forward leaf pivot bushings RS575 and 3.2” long sleeve RS454 from Kit RS746 or RS741 into the eye loop closest to the center pin of new Rancho Leaf spring RS44148.

Use a thin coat of synthetic grease. See Illustration 13.

Forward Pivot

3.2” Sleeve — RS454

Wide Bushing - RS575

Rear Loop

2.74” Sleeve – RS4200724

Narrow Bushing – RS626

RS44148

Nut

Mounting Loop

Washers

Illustration 10

Bolt

Illustration 11

7)

Lower mount will look like Illustration 12 when done.

SHORT LONG

Illustration 13

2)

Press smaller leaf bushings RS626 and 2.74” long sleeve RS400724 from Kit RS746 or RS741 into the eye loop furthest from the center pin of new Rancho leaf spring RS44148.

Use a thin coat of synthetic grease.

3)

Press bushings RS626 and 2.84” long sleeve

RS420111 from bag RS860791 into new Rancho rear shackle

RS176767. Use a thin coat of synthetic grease.

4)

Support the rear axle with a floor jack to relieve the tension on the leaf spring.

5)

Remove the rear shock absorbers.

6)

If equipped disconnect sway bar end link from u-bolt anchor plate. See Illustration 14

RS176409

USS Washers

OE Bump Stop

End Link

Anchor Plate

Illustration 12

U-Bolts

Illustration 14

RS7500

Note: Remove and install one leaf spring assembly at a time to prevent the rear axle from tipping.

7)

Loosen all the rear axle U-bolt nuts, but do not remove.

8)

Starting with one side, remove rear axle U-bolts and anchor plate.

12

10)

Remove the leaf spring bolts at the forward spring pivot and shackle.

Forward Spring Pivot

RS176409 &

Bump Stop

RS176767

RS44148

Illustration 15

11)

Carefully lower the rear axle enough to remove the leaf spring from the vehicle. Do not allow the axle to hang from any brake lines or cables.

12)

Remove shackle from frame.

13)

Using OE hardware, loosely install bushing end of shackle RS176767 to frame mount.

14)

Attach forward pivot loop of leaf (wider bushings & sleeve) to frame pivot and rear loop to shackle. Use OE hardware. Do not tighten until vehicle is on ground at ride height.

15)

Insert leaf shim RS7500 between axle and leaf spring with the thin end forward and attach the spring assembly to the axle with OE anchor plate and new U-bolts, washers and nuts from kit RS746 or RS741. Do not tighten at this time. See

Illustration 16

Anchor Plate

Illustration 16

16)

Repeat steps 9-12 for other side of vehicle.

17)

Tighten U-bolt nuts to 55 Ft-Lbs.

RS7500

U-Bolts

18)

Install shock absorbers and torque upper nuts to 15 Ft-

Lbs, and lower nuts to 44 ft-lbs.

19)

Reconnect brake hose to axle with axle vent fitting and reattach vent hose.

20)

Reattach sway bar end link and torque to 55 Ft-Lbs.

B

UMP

S

TOP

D

ROP

B

RACKET

I

NSTALLATION

1)

Remove OE bump stops from frame. See Illustration 14 and Illustration 15.

2)

Attach OE bump stops to Rancho rear bump stop bracket RS176409 using 8MM hardware from bag RS860796.

Use 5/16 USS washer against bracket RS176409. Torque to 20

Ft-Lbs.

3)

Attach bracket and bump stop assembly to frame using

OE hardware and 5/16 USS washer against bracket RS176409.

Torque to 20 Ft-Lbs.

L

OWER

V

EHICLE AND

F

INAL CHECKS

1)

Install the rear wheels and lower the vehicle to the ground. Tighten lug nuts to 80-110 FT-LBS. Do not release parking brake or remove wheel chocks.

2)

Jounce vehicle to settle springs. Torque leaf spring and shackles to 80 Ft-Lbs.

3)

Turn the front wheels completely left then right. Verify adequate tire, wheel, and brake hose clearance. Inspect steering and suspension for tightness and proper operation.

4)

With the suspension at maximum extension (full droop), inspect and rotate all axles and drive shafts. Check for binding and proper slip yoke insertion. The slip yoke should be inserted a minimum of one inch into the transfer case and/or transmission.

5)

Ensure that the vehicle brake system operates correctly.

If new brake hoses were installed, verify that each hose allows for full suspension movement.

6)

Readjust headlamps.

7)

Have vehicle aligned to manufacturer’s specifications.

Recommended Alignment Specifications

Caster (degrees): 7.00° ± 1.50°

Camber (degrees): -0.25° ± 0.50°

Sum Toe In (degrees): 0.25° ± 0.25° or 0.10” ± 0.10”

13

8)

Park the vehicle on a level surface Measure and record the distance from the center of each wheel to the top of the fender opening. See Illustration 17 and Illustration 2. Record

these measurements in the space provided.

Front Components

Lower Control Arm

Upper Control Arm

Shock Mount, Upper

Shock Mount, Lower

Coil Spring Retainer

Bump Stop Mount

Track Bar Upper (Ball Stud)

Track Bar Lower (Axle Bracket)

Drag Link to Pitman Arm

Sway Bar Clevis

Sway Bar End Link

Brake Hose to Caliper

Wheels (Lug Nuts)

135 ft. lbs.

45 ft. lbs.

10 ft. lbs.

14 ft. lbs.

16 ft. lbs.

31 ft. lbs.

35 ft. lbs.

45 ft. lbs.

35 ft. lbs.

35 ft. lbs.

60 ft. lbs.

23 ft. lbs.

80-110 ft. lbs.

Illustration 17

Torque Specs

Leaf Spring & Shackle

Leaf Spring U-bolt

Shock Absorber Upper

Shock Absorber Lower

Sway Bar Link

Bump Stop

Wheels (Lug Nuts)

Rear Components

80 ft. lbs.

55 ft. lbs.

15 ft. lbs.

44 ft. lbs.

55 ft. lbs.

20 ft. lbs

80-110 ft.lbs

14

15

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